Mercury Removal from Liquid Hydrocarbons via Chemical Phase Separation

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Solution Overview

Problem

Current separation methods using additives in hydrocarbons are ineffective in removing mercury due to the presence of submicron particulate matter and various forms of mercury species, requiring significant mixing energy and extended residence time.

Innovation Solution

A system and method involving chemical additives, such as thiols and sulfur donating compounds, are introduced into hydrocarbon mixtures to promote a chemical reaction, separating mercury into a water phase, thereby reducing mercury content in the crude oil.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If current separation methods using additives are used, then the process is simple, but mercury removal effectiveness is poor

Engineering Contradiction:

Improvemercury removal effectivenessVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention segments the mercury removal process into distinct stages: chemical reaction stage (additive injection and mixing), settling stage (phase separation), and removal stage (skimming offmercury-containing layer). This segmentation transforms a single ineffective separation step into a multi-stage process where each stage addresses specific challenges, thereby improving mercury removal effectiveness while maintaining operational simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces chemical additives as intermediaries that facilitate mercury removal. These additives react with mercury to form mercury-containing compounds that separate into distinct phases, enabling effective removal. The additives act as mediators between the hydrocarbon mixture and mercury, solving the effectiveness problem without requiring complex equipment

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If prior art additives are used, then the process requires less mixing energy, but mercury removal is incomplete

Engineering Contradiction:

Improvemercury removal completenessVSAvoidmixing energy

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The invention changes key parameters of the separation process: using specific chemical additives that react with mercury to alter its chemical form, adjusting mixing intensity to optimize reaction efficiency, and controlling settling time to ensure complete phase separation. These parameter changes enable complete mercury removal while optimizing energy consumption by avoiding excessive mixing

Inventive Principle:

Principle #35Parameter changes

3Reliability

If extended residence time is used, then mercury removal is more complete, but processing productivity decreases

Engineering Contradiction:

Improvemercury removal completenessVSAvoidprocessing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention applies preliminary action by injecting chemical additives that pre-react with mercury to form separable compounds before the settling phase. This preliminary chemical transformation accelerates the overall process by creating distinct phases that separate quickly, reducing the residence time needed while ensuring complete mercury removal

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces prolonged mechanical mixing with chemical reaction mechanisms. Instead of relying on extended mechanical agitation to achieve separation, the chemical additives transform mercury into compounds that naturally separate through density differences, dramatically reducing the time required while maintaining removal completeness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method effectively reduces mercury levels in hydrocarbons by forming distinct phases, allowing for efficient separation and significant reduction of mercury in crude oil and condensates.

Implementation Method 1

The one or more chemical additives promote a chemical reaction within the hydrocarbon mixture to form a top layer comprising crude oil with a reduced mercury content relative to the initial level of mercury in the hydrocarbon mixture and a bottom layer comprising water and at least one mercury containing compound(s)

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding